Value Stream Map

Value Stream Mapping of a Complete Product

What is Value Stream Mapping (VSM)?

• A ‘Value Stream’ (VS) is “all the actions (both value--added and non-value-added) currently required to bringa product through the main flows essential to everyproduct” (Rother & Shook, 1999, p. 3).

• Value Stream Mapping (VSM) is “the process of mappingthe material and information flows of all components and subassemblies in a value stream that includes manufacturing, suppliers, distribution and thecustomer”.

Power of Value Stream Mapping (VSM)

• VSM is a mapping tool that maps not only material flowsbut also information flows that signal and control thematerial flows.

• This visual representation facilitates the process for implementation of Lean Thinking by helping to identifythe value-adding steps in a value stream and eliminatingthe non-value adding steps, or waste (muda) in flowpaths of products.

An Example of a Current State Map

An Example of a Future State Map

Advantages of Value Stream Mapping

• Relates the manufacturing process steps to other componentsof the supply chain viz. distributors, suppliers andproduction control.

• Integrates material and information flows.

• Links Production Control and Scheduling (PCS) functionsto Shopfloor Control.

• Integrates various IE techniques for material and information flow analysis.

Disadvantages of Value Stream Mapping

• Fails to map multiple products that do not have identicalroutings.

• Fails to relate plant layout and/or material handlingto process and equipment parameters.

• Lacks any economic measure for “value”.

• Lacks the spatial structure of the facility layout.

• Biased towards high-volume low-varietymanufacturing systems.

• Fails to capture the time value (in $) of the flow delaysdue to setup, processing, queuing (at each process step),material handling, etc. delays due to capacity constraintsand order sequencing at each process step.

Basis for Value Network Mapping (VNM)

• Developed for products with complex BOM’s that have many components and several assembly levels.

• Developers of VSM state that “many value streams havemultiple flows that merge. Draw such flows over oneanother. But do not try to draw every branch if there aretoo many. Choose the key components first, and get theothers later if you need to” (Rother & Shook, 1999, p. 19).

Where to use Value Network Mapping

Raw

Materials

Finished

Goods

Pro

du

ctio

n F

low

s in

th

e

Ma

nu

fact

uri

ng

Sy

stem

s

C1 C3C2 C4 C5 C6 C7 C8 C9 C10

SA 2 SA 3 SA 4 SA 5SA 1

C11

COMPONENTS

SUB ASSEMBLIES

ASSEMBLIES

VSM APPLIES VERY WELL AT

THIS LEVEL

VNM APPLIES VERY WELL AT

THIS LEVEL

ASSEMBLY2

ASSEMBLY1

Our Goal

• To use our method to map the complete network of flowsfor a complex product or large sample of parts.

• To computerize basic Industrial Engineering (IE) tools formaterial flow mapping, using a software package formaterial flow analysis - PFAST (Production Flow Analysisand Simplification Toolkit).

• To integrate the material flow mapping power of PFASTwith a Finite Capacity Scheduling (FCS) software.

Fundamental Challenges in VNM

• How/where to locate the process boxes (representing the variousworkcenters) on the map without creating a “spaghetti look”?

• How to show the exact routing for (and identify) each value stream?

• How to identify the families of parts and sub-assemblies based onsimilarity of their manufacturing routings? � Group Technology!

• How to design a network of cells linked together into a POUS (Point Of Use Storage) factory layout to achieve “Flow”?

• Where to locate (i) the supermarkets to store groups of raw materials(ii) the supermarkets to store kits of parts for different sub-assemblies and (iii) the time buffers at the capacity constraints?

• How to schedule and synchronize the production of the different value streams that require capacity on common workcenters?

• How to compute the VAR (Value Added Ratio) for the entire network?

Value Network Map for a Machining Cell

EXERCISE

Problem Statement

How does one draw the Value Stream Map of a

single product given:

1. the Bill Of Materials (BOM) for the product,

2. the manufacturing routings for the

components, subassemblies and the final

product?

Overview of the Method for a Single Product

235701

235201

235202

235204

235205

235206

235207

235208

235209

235305

235102 SA

235101

235103 235203

235301

235302 235303 235304

BILL OF MATERIAL AND GOZINTO CHART FOR WOUND ROTOR

Indented BOM for the Product

• How/where to locate the process boxes (representing the variousworkcenters) on the map without creating a “spaghetti look”?

• How to show the exact routing for (and identify) each value stream?

• How to identify the families of parts and sub-assemblies based onsimilarity of their manufacturing routings? � Group Technology!

• How to design a network of cells linked together into a POUS (Point Of Use Storage) factory layout to achieve “Flow”?

• Where to locate (i) the supermarkets to store groups of raw materials(ii) the supermarkets to store kits of parts for different sub-assemblies and (iii) the time buffers at the capacity constraints?

• How to schedule and synchronize the production of the different value streams that require capacity on common workcenters?

• How to compute the VAR (Value Added Ratio) for the entire network?

Contents of a Value Network Map

Input Data to PFAST

763IRONW->763DRLPR->763WELDM->770WHLBR->771HCFIN->811ASMLY12TN20244416

764PSMAP->764PSMAO->763DRLPR->763WELDM->770WHLBR->771HCFIN->811ASMLY11TC201501-10515

763SHR16->761PUNCH->763PRBRK->764WELDM->763WELDM->770WHLBR->771HCFIN->811ASMLY11TB20197014

761PUNCH->761DBURR->761FORM2->761TWELD->761POLSH->761ASMLY->811ASMLY11TB10042313

761PUNCH->761DBURR->761HSTUD->761SPWLD->761ASMLY->811ASMLY12TB10041612

761PUNCH->761DBURR->761FORM2->761TWELD->761POLSH->761HSTUD->761SPWLD->761ASMLY->811ASMLY11TB100413-511

763BDSAW->763ACRO->763WELDM->770WHLBR->771HCFIN->811ASMLY14TA20196910

763BDSAW->763ACRO->771VIKIN->763WELDM->770WHLBR->771HCFIN->811ASMLY12TA2019689

763BDSAW->771VIKIN->763WELDM->770WHLBR->771HCFIN->811ASMLY12TA2019678

763SHR16->763IRONW->763PRBRK->763WELDM->770WHLBR->771HCFIN->811ASMLY11T2022757

763SHR16->763PRBRK->763WELDM->770WHLBR->771HCFIN->811ASMLY12T201972-67006


763SHR16->761PUNCH->763PRBRK->763WELDM->770WHLBR->771HCFIN->811ASMLY11T201966-47384




RoutingRevenueQuantityPartNo.

Q-type From-To Chart from PFAST

1764PSMAO

1764PSMAP

2761FORM2

2761TWELD

11761POLSH

4761ASMLY

3761SPWLD

3761HSTUD

22761DBURR

42761PUNCH

1764WELDM

3763DRLPR

21763IRONW

219763SHR16

111763PRBRK

23763WELDM

23770WHLBR

23771HCFIN

811ASMLY

62763BDSAW

42763ACRO

4771VIKIN

764P

SM

AO

764P

SM

AP

761F

OR

M2

761T

WE

LD

761P

OL

SH

761A

SM

LY

761S

PW

LD

761H

ST

UD

761D

BU

RR

761P

UN

CH

764W

EL

DM

763D

RL

PR

763IR

ON

W

763S

HR

16

763P

RB

RK

763W

EL

DM

770W

HL

BR

771H

CF

IN

811A

SM

LY

763B

DS

AW

763A

CR

O

771V

IKIN

W/C

PR Analysis Type II from PFAST

PR Analysis Type IV from PFAST

811ASMLY761ASMLY761POLSH761TWELD761FORM2761DBURR761PUNCHTB100423

811ASMLY761ASMLY761SPWLD761HSTUD761POLSH761TWELD761FORM2761DBURR761PUNCHTB100413-5

811ASMLY761ASMLY761SPWLD761HSTUD761DBURR761PUNCHTB100416

811ASMLY771HCFIN770WHLBR763WELDM763ACRO763BDSAWTA201969

811ASMLY771HCFIN770WHLBR763WELDM771VIKIN763ACRO763BDSAWTA201968

811ASMLY771HCFIN770WHLBR763WELDM771VIKIN763BDSAWTA201967

811ASMLY771HCFIN770WHLBR763WELDM763DRLPR764PSMAO764PSMAPTC201501-105

811ASMLY771HCFIN770WHLBR763WELDM763DRLPR763IRONWTN202444

811ASMLY771HCFIN770WHLBR763WELDM763PRBRK763IRONW763SHR16T202275

811ASMLY771HCFIN770WHLBR763WELDM763PRBRK763SHR16T201972-6700


811ASMLY771HCFIN770WHLBR763WELDM764WELDM763PRBRK761PUNCH763SHR16TB201970

811ASMLY771HCFIN770WHLBR763WELDM763PRBRK761PUNCH763SHR16T201966-4738




Parts

770WHLBR

771HCFIN

763WELDM

TB201990 TB600364-1

TC201989-1

TC202034 -1

510624370MN31004

MZ0901010035MZ0901010289

MZ0901010379MZ0909000050

TB100395

13640300A

MZ0901010091

MZ0901010166

TA800218

TN100429

TN100430

TN100432TB100408-5

TB100423TB100426

MZ060200142

TN201975

TN800587

TN800654

A14691400A TA800634 TB800629 - 7

811ASMLY

MZ0901020056

761ASMLY

771HCFIN

770WHLBR

763WELDM

TA201968 TA201969 TA201967 TC201501-105 TN202444 T201962-6544 T201963-6431 T201965-4738T202275-6544 T201966-4738

TA201974 TB201971 T201972-6700T201972-4300

761PUNCH

763PRBRK

763SHR16

764WELDM

763ACRO

771VIKIN

763BDSAW

764PSMAO

764PSMAP

763DRLPR

763IRONW

761PUNCH

763PRBRK

763SHR16

761SPWLD

761HSTUD

761DBURR

761PUNCH

761FORM2

761TWELD

761POLSH

Sub-netw ork 1

Sub-netw ork 2

Sub-netw ork 3

Aggregation of Value Streams into Sub-networks

Production Schedule for the Value Network Map

TB201990

TC201989-1

TC202034 -1

TB100395

TB100408-5

TB100413-5

MZ1304020031

TB100416

MZ1304020009

TB100423

MZ1304020009

811ASMLY (1.5)

770WHLBR (0.1)

771HCFIN (0.75)

763WELDM (2.5)

761ASMLY (0.1)

771HCFIN (0.5)

770WHLBR (0.1)

763WELDM (0.5)

TA201968

MZ1307010089

763ACRO (0.01)

771VIKIN (0.01)

763BDSAW (0.01)

TA201969

MZ1307020040

763BDSAW (0.017)

763ACRO (0.01)

TA201967

MZ1307010089

763BDSAW (0.01)

771VIKIN (0.01)

TC201501-105

MZ1302010028

764PSMAO (0.05)

763DRLPR (0.02)

764PSMAP (0.48)

TN202444

MZ1307010001

763IRONW (0.01)

763DRLPR (0.02)

T202275-6544

MZ1301010034

763IRONW (0.02)

763PRBRK (0.02)

763SHR16 (0.01)

T201966-4738

MZ1301010034

761PUNCH (0.02)

763PRBRK (0.03)

763SHR16 (0.01)

TB201971

TB201970

MZ1301010034

764WELDM (0.15)

T201972-6700

MZ1304010054

763SHR16 (0.01)

763PRBRK (0.01)

T201972-4300

MZ1304010054

763SHR16 (0.01)

763PRBRK (0.01)

761SPWLD (0.033)

761HSTUD (0.02)

761DBURR (0.002)

761PUNCH (0.017)

761FORM2 (0.007)

761TWELD (0.016)

761POLSH (0.01)

761DBURR (0.002)

761PUNCH (0.02)

761FORM2 (0.009)

761TWELD (0.031)

761POLSH (0.019)761PUNCH (0.1)

763PRBRK (0.02)

763SHR16 (0.01)

761DBURR (0.0005)

761PUNCH (0.005)11

12 13

1415

16

17 18 19

20

21

22C

max= 5.63 hours

7654321 T201965-4738

MZ1301010034

763SHR16 (0.01)

763PRBRK (0.02)

10T201963-6431

MZ1301010034

763SHR16 (0.01)

763PRBRK (0.02)

9T201962-6544

MZ1301010034

763SHR16 (0.01)

763PRBRK (0.02)

8

(1) Start with the job that has the Shortest Processing Time (SPT Dispatching Rule)

Tie Breaking Rule #1: Choose the job in the group (or subassembly) that has the Most Work Remaining (MWKR Dispatching Rule)

Tie Breaking Rule #2: Choose the job with the Smallest Job Index

(2) Repeat Step (1) until all jobs have been scheduled

764BDSAW 1 3 20.01 0.02 0.037

764PSMA 40.53

763ACRO 1 20.02 0.047

763DRPLPR 5 40.03 0.55

763IRONW 5 60.01 0.03

763SHR16 16 6 7 8 9 10 18 190.04 0.05 0.06 0.07 0.08 0.09 0.1 0.11

771VIKIN 1 30.03 0.04

763WELDM 20 110.78 3.28

764WELDM 170.28

763PRBRK 16 18 19 6 7 8 9 100.13 0.14 0.15 0.17 0.2 0.22 0.24 0.26

761PUNCH 16 12 13 14 70.11 0.13 0.135 0.152 0.172

770WHLBR 20 110.88 3.38

761DBURR 12 13 140.132 0.1355 0.154

761FORM2 12 140.141 0.161

761TWELD 12 140.172 0.186

761POLISH 12 140.191 0.201

761HSTUD 150.211

761SPWLD 150.244

761ASMLY 210.344

771HCFIN 20 111.38 4.13

811ASMLY 225.63

Cmax = 5.63 hrs.

Explanation of the Gantt Chart:

(1) Jobs with same color code are the Completion Time (Ci) of each job at the same level (sub-assembly)

(2) Jobs with bold frame are the Makespan (Maximum Completion Time, Cmax) at each level (sub-assembly) in the (hierarchical) production schedule

Assumptions:

(1) Travel distances between workcenters are negligible and inter-operation transfer delays are zero. Ahem! Ahem!

(2) Changeover (or set-up) time for any operation is zero. Ahem! Ahem!

Acknowledgement:

The author gratefully acknowledges the assistance of ISE students (ISE533, Spring2005), Tom Chia and Dustin Converse, who developed the original version of this schedule

Facility Design using the Value Network Map

763SHR16 761PUNCH

763PRBRK

763/764WELDM 770WHLBR 771HCFIN

763IRONW

763DRLPR764PSMA

763BDSAW 763ACRO 771VIKIN

761DBURR 761FORM2 761POLISH 761HSTUD 761SPWLD

761ASMLY

811ASMLY

761TWELD

Preliminary Drawing of Value Network Map(without Sub-networks)

763SHR16

761PUNCH

763PRBRK 763/764WELDM 770WHLBR 771HCFIN

763IRONW 763DRLPR

764PSMA 763BDSAW

763ACRO 771VIKIN

761DBURR 761FORM2 761POLISH 761HSTUD 761SPWLD

761ASMLY

811ASMLY

761TWELD

Sub-netw ork 1

Sub-netw ork 2

Sub-netw ork 3

Final Drawing of Value Network Map(with Sub-networks)

811ASM761

POLSH

761

SPWLD

761ASY

761

DBURR

761

TWELD

761

HSTUD/

761PEM

761

FORM

761PUNCH

763SHR16 763PRBRK

763DRLPR

764PSMA

771

VIKIN

764/763 WELDM

763BDSAW

763ACRO

Sub-network 3

Sub-network 1

Sub-network 2

763IRONW

Point-Of-Use (POU) Facility Layout based on Value Network Map

Extension to Multiple Product BOMs

PRODUCT

A

PRODUCT

B

A1 A2 A3 B1 B2 B3

A

2-1

A

2-2

A

2-3

A

3-1

A

3-2

B

2-1

B

2-2

B

2-3

F1 F2 F3 F4

G1 G2

Relationship Between Different Product BOM's,Part Families (F), and Groups of Part Families (G)

Fi=Family of Parts Gj=Group of Part Families

Documents

Value Stream Map